Methods and systems for producing activated silicate based materials using sustainable energy and materials

ABSTRACT

A method and system for producing highly activated silicate material, wherein the silicate source material is provided for reaction with a reforming agent in a reforming process. The reforming process is a hydrothermal process and/or a high temperature silicate reforming (HTSR) process. A heat source heats reaction materials to a reaction temperature in the presence of a reaction medium. For the hydrothermal reaction process, the reaction medium and heat source are an exhausted steam that is a byproduct of another industrial process. For the HTSR process, the silicate source material and the heat source are a molten slag byproduct from another industrial process.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 16/333,759, filed Mar. 15, 2019, which is a 371 national stageapplication of PCT/US2017/052239, filed Sep. 19, 2017, which claims thebenefit of U.S. Provisional Application No. 62/396,690, filed Sep. 19,2016, which is incorporated by reference as if disclosed herein in itsentirety.

BACKGROUND

A large quantity of useful and valuable elements, such as Ca, Mg, Fe,Al, Si, etc., are stored in different kinds of silicate minerals, suchas Serpentine, Wollastonite, Olivine, etc., and industrial silicatewastes, such as slag, mine tailing and fly ash etc. After beingextracted from the silicate based materials, these elements can beemployed to produce different chemicals, such as carbonates,oxides/hydroxides, halides, etc., which are critical for many industrialprocess, such as chemical process, and metallurgical process, etc.

However, since the reactivity of the natural silicate mineral is nothigh enough, the material and the energy consumption of traditionalelemental extraction processes are normally high, leading to a highprocess cost, while the process kinetics and the conversion arerelatively low. Methods need to be developed to enhance the materialreactivity, so that the process kinetics and the conversion can beimproved, while the cost due to the material and the energy consumptioncan be well controlled to achieve overall economic feasibility.Preferably, the method can be built up on sustainable utilization ofmaterial and energy.

SUMMARY

Some embodiments of the disclosed subject matter are directed to amethod of producing an activated silicate material. In some embodiments,a silicate source material is provided and intermixed with a reformingagent. In some embodiments, heat is provided to the silicate sourcematerial and reforming agent under conditions configured to initiate areforming reaction. In some embodiments, the heat is a byproduct fromanother process, e.g., waste heat from an industrial process.

The reforming process yields an activated silicate material. In someembodiments, the reforming process is a hydrothermal process. In someembodiments, the reforming process is a high temperature silicatereforming (HTSR) process. Value materials are then extracted from theactivated silicate material via an elemental extraction process. In someembodiments, the elemental extraction process is a mineral carbonationprocess, oxides/hydroxide production process, halide production process,ferrous metal production process, nonferrous metal production process,rare earth production process, etc., or a combination thereof. In someembodiments, the activated silicate material is cooled prior to theelemental extraction process. In some embodiments, the reforming agentis recycled after value materials are removed from the activatedsilicate material.

Some embodiments of the present disclosure are directed to a system forproducing the activated silicate material discussed above. In someembodiments, the system includes a reaction chamber in communicationwith a source of silicate material, a source of reforming agent, areaction medium, and a source of heat. In some embodiments, the systemincludes an activated silicate material output in configuration with anelemental extraction module configured to extract value materials fromthe activated silicate material.

Some embodiments of the disclosed subject matter are directed to amethod of innovative industrial waste energy utilization for silicatebased material activation. In some embodiments, exhausted steam is usedas both part of the reaction medium and the heat source for thehydrothermal process. In some embodiments, molten slag byproduct fromanother process serves as both the silicate source material and the heatsource for the HTSR process.

Some embodiments of the disclosed subject matter are directed to amethod of molten slag heat utilization (MSHU) to conduct endothermicprocesses. In some embodiments, molten slag byproduct from anotherprocess is intermixed with the reforming agents to conduct the HTSRprocess with the molten slag heat. In some embodiments, molten slagbyproduct is intermixed with coal and water to conduct the coalgasification process with the molten slag heat. In some embodiments,molten slag byproduct is intermixed with methane and water to conductthe steam reforming process with the molten slag heat.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings show embodiments of the disclosed subject matter for thepurpose of illustrating the invention. However, it should be understoodthat the present application is not limited to the precise arrangementsand instrumentalities shown in the drawings, wherein:

FIG. 1 is a schematic drawing of a system for producing highly activatedsilicate material according to some embodiments of the presentdisclosure;

FIG. 2A is a chart of a method of producing highly activated silicatematerial according to some embodiments of the present disclosure;

FIG. 2B is a chart of a method of producing highly activated silicatematerial according to some embodiments of the present disclosure;

FIG. 3 is a schematic drawing of a system for producing highly activatedsilicate material according to some embodiments of the presentdisclosure;

FIG. 4A portrays Mg extraction conversions of serpentine relatedmaterials using methods according to some embodiments of the presentdisclosure;

FIG. 4B portrays Si extraction conversions of serpentine relatedmaterials using methods according to some embodiments of the presentdisclosure;

FIG. 4C portrays Fe extraction conversions of serpentine relatedmaterials using methods according to some embodiments of the presentdisclosure;

FIG. 4D portrays Ca extraction conversions of wollastonite relatedmaterials using methods according to some embodiments of the presentdisclosure;

FIG. 4E portrays Si extraction conversions of wollastonite relatedmaterials using methods according to some embodiments of the presentdisclosure;

FIG. 5A portrays elemental extraction conversions of serpentine relatedmaterials using methods according to some embodiments of the presentdisclosure;

FIG. 5B portrays elemental extraction conversions of wollastoniterelated materials using methods according to some embodiments of thepresent disclosure;

FIG. 5C portrays elemental extraction conversions of iron slag relatedmaterials using methods according to some embodiments of the presentdisclosure;

FIG. 5D portrays elemental extraction conversions of steel slag relatedmaterials using methods according to some embodiments of the presentdisclosure;

FIG. 6A portrays elemental extraction conversions of serpentine relatedmaterials with different reaction time using methods according to someembodiments of the present disclosure;

FIG. 6B portrays elemental extraction conversions of serpentine relatedmaterials with different reaction atmosphere using methods according tosome embodiments of the present disclosure;

FIG. 6C portrays elemental extraction conversions of serpentine relatedmaterials with different cooling process using methods according to someembodiments of the present disclosure;

FIG. 7 portrays elemental extraction conversions of serpentine relatedmaterials with different reforming agents using methods according tosome embodiments of the present disclosure;

FIG. 8A portrays elemental extraction conversions of serpentine relatedmaterials using methods according to some embodiments of the presentdisclosure; and

FIG. 8B portrays elemental extraction conversions of wollastoniterelated materials using methods according to some embodiments of thepresent disclosure.

DETAILED DESCRIPTION

Referring now to FIG. 1, aspects of the disclosed subject matter includea system 100 for producing activated silicate material. In someembodiments, system 100 includes a reaction chamber 102 for reacting asilicate source material with a reforming agent. In some embodiments, aplurality of reaction chambers 102 are operated in parallel. In someembodiments, a plurality of reaction chambers 102 are operated inseries. In some embodiments, system 100 includes a silicate materialinput 104 in communication with reaction chamber 102 which provides thesilicate source material to the reaction chamber. In some embodiments,the silicate source material includes a calcium mineral, a magnesiummineral, slag, mine tailing, fly ash, kiln dust, or a combinationthereof. In some embodiments, the silicate source material is naturallyoccurring, such as serpentine, olivine, wollastonite, etc., or acombination thereof. In some embodiments, the silicate source materialis a byproduct of another industrial process. In some embodiments, thesilicate source material is a solid. In some embodiments, the silicatesource material is a slurry, as will be described in greater detailbelow.

In some embodiments, system 100 includes a reforming agent input 106 incommunication with reaction chamber 102 which provides a source ofreforming agent to the reaction chamber. As will be discussed in greaterdetail below, in some embodiments the reforming process is ahydrothermal process. In some embodiments, the reforming process is aHTSR process. In some embodiments, the hydrothermal reforming agentincludes sodium hydroxide (NaOH), potassium hydroxide (KOH), ammoniumhydroxide (NH₄OH), lithium metaborate (LiBO₂), lithium tetraborate(Li₂B₄O₇), sodium carbonate/bicarbonate (Na₂CO₃/NaHCO₃), potassiumcarbonate/bicarbonate (K₂CO₃/KHCO₃), ammonium carbonate/bicarbonate((NH₄))₂CO₃/(NH₄)HCO₃), or a combination thereof. In some embodiments,the HTSR reforming agent is composed acidic, basic, or neutral reformingagents. In some embodiments, acidic reforming agents for HTSR includeboron trioxide (B₂O₃), lithium tetraborate (Li₂B₄O₇), silica (SiO₂),ammonium (NH⁴⁺) based acidic salts, etc., or combinations thereof. Insome embodiments, basic reforming agents for HTSR include, borax(Na₂B₄O₇.10H₂O), lithium metaborate (LiBO₂), sodium hydroxide (NaOH),potassium hydroxide (KOH), sodium carbonate/bicarbonate (Na₂CO₃/NaHCO₃),ammonium based base and basic salts, etc., or combinations thereof. Insome embodiments, neutral reforming agents for HTSR include sodiumchloride (NaCl), fluorite (CaF₂), alumina (Al₂O₃), ammonium basedneutral salts, etc., or combinations thereof.

In some embodiments, system 100 includes a reaction medium input 108 incommunication with reaction chamber 102 which provides a reaction mediumto the reaction chamber. In some embodiments, the reaction medium is anindustrial plant exhaust source, air source, nitrogen gas source, oxygengas source, carbon monoxide gas source, or a combination thereof.

In some embodiments, system 100 includes a heat source 110 configured toprovide heat to the system. In some embodiments, heat from heat source110 is a byproduct from another process that is recycled for use insystem 100. In some embodiments, heat from heat source 110 is waste heatfrom a separate process, e.g., from industrial power production. In someembodiments, heat source 110 is an industrial energy production source,an industrial energy production process, waste energy source, molteniron slag, molten steel slag, a flue gas, an exhaust gas, exhaustedsteam, or a combination thereof. In some embodiments, system 100includes at least one heat exchanger 110′ configured to communicate heatfrom heat source 100 to the system.

In some embodiments, system 100 includes an activated silicate materialoutput 112 from reaction chamber 102. Activated silicate material output112 is in communication with and provides activated silicate material toan elemental extraction module 114. As will be discussed in greaterdetail below, elemental extraction module 114 is configured to extractvalue materials 116 from the activated silicate material utilizing oneor more extraction processes. In some embodiments, elemental extractionmodule 114 performs a mineral carbonation process, oxides/hydroxideproduction process, halide production process, ferrous metal productionprocess, nonferrous metal production process, rare earth productionprocess, or a combination thereof. In some embodiments, elementalextraction module includes all additional components necessary tofacilitate value material recovery using these processes. Valuematerials that can be extracted from the activated silicate materialusing the systems and methods of the present disclosure include, but arenot limited to, Ca, Mg, Al, Fe, Si, rare earth elements, etc.; oxidesand hydroxides of Al, Fe, Ti, Mn, etc.; metal carbonates; silicates andsilica; or combinations thereof.

In some embodiments, system 100 includes a process module 118. In someembodiments, process module 118 is in communication with thenon-activated silicate material source. In some embodiments, processmodule 118 is in communication with heat source 110. In someembodiments, process module 118 is in communication with reactionchamber 102. Process module 118 is configured to initiate anon-silicate-activation process. In some embodiments, thenon-silicate-activation process is performed separately from thesilicate activation process. In some embodiments, thenon-silicate-activation process is performed concurrently with thesilicate activation process. In some embodiments, thenon-silicate-activation process utilizes the components of system 100,e.g., heat from molten slag via MSHU, which is discussed in greaterdetail below.

In some embodiments, system 100 includes one or more conduits 120connecting system components such as silicate material input 104,reforming agent input 106, reaction medium input 108, elementalextraction module 114, etc. In some embodiments, the system includes acooling apparatus 122 for cooling the activated silicate material afterreforming the silicate source materials. Referring now to FIG. 2A, someembodiments of the present disclosure are directed to a method 200 ofproducing activated silicate material. At 202, a silicate sourcematerial is provided. At 204, heat is provided to drive a reformingreaction of the silicate source material with a reforming agent. Asdiscussed above, in some embodiments, the heat provided for thereforming reaction is waste heat from another process.

At 206, the silicate source material is reformed to an activatedsilicate material with the reforming agent via the reforming reaction.As discussed above, in some embodiments, the reaction occurs in areaction chamber, such as reaction chamber 102 described above. Also asdiscussed above, in some embodiments, the reforming step 206 is ahydrothermal process 206′. Referring specifically to hydrothermalprocess 206′, the silicate source material and reforming agent areintermixed with a liquid to produce a slurry. In some embodiments, theliquid is water. In some embodiments, the water-based slurry is mixed toa density of about 10 percent by weight to about 20 percent by weightsolids. In some embodiments, the water-based slurry is mixed to adensity of about 15 percent by weight solids. In some embodiments, theweight ratio of silicate source material to reforming agent is fromabout 1:1 to about 100:1. As discussed above, heat is applied at 204 tothe slurry. In some embodiments, heat is applied 204 to bring thereaction temperature to about 100° C. to about 300° C. for hydrothermalprocess 206′. In some embodiments, heat is applied 204 to bring thereaction temperature to about 120° C. to about 250° C. for hydrothermalprocess 206′. In some embodiments, hydrothermal process 206′ isperformed under pressurized conditions. In some embodiments, thereaction chamber is pre-pressurized, e.g., with air or nitrogen gas. Insome embodiments, hydrothermal process 206′ has a reaction time of about1 hour to about 3 hours. In some embodiments, hydrothermal process 206′has a reaction time of about 2 hours. In some embodiments, the silicatesource material and reforming agent are intermixed with exhausted steam.In these embodiments, integrated exhausted steam can advantageously actas both the slurry-producing liquid and the heat source at 204. Theoverall advantages of the systems and methods of the present disclosureare discussed in greater detail below.

In some embodiments, the reforming step 206 is an HTSR process 206″.Referring specifically to HTSR process 206″, the silicate sourcematerial and reforming agent are intermixed at a high reaction temperateusing heat provided at 204. In some embodiments, the weight ratio ofsilicate source material to reforming agent is from about 0.1:1 to about100:1. The heat applied 204 to bring the reaction temperature to about300° C. to about 1500° C. In some embodiments, the reaction temperatureis not lower than the melting temperature of the reforming agent. Insome embodiments, HTSR process 206″ has a reaction time of about 1minute to about 12 hours. In some embodiments, the reforming reaction ofHTSR process 206″ is performed in an anhydrous environment. In someembodiments, the reforming agent is intermixed with molten slag. Inthese embodiments, molten slag advantageously acts as both the silicatesource material and the heat source at 204. In some embodiments, HTSRprocess 206″ includes intermixing additional silicate source materialswith the reforming agent and the molten slag (not pictured).

At 208, in some embodiments, the activated silicate material issubjected to an elemental extraction process. Elemental extractionprocess 208 extracts value materials from the activated silicatematerial. The reforming 206 improves the kinetics and conversion ofelemental extraction process 208. As discussed above, elementalextraction process 208 is a mineral carbonation process,oxides/hydroxide production process, halide production process, ferrousmetal production process, nonferrous metal production process, rareearth production process, etc., or a combination thereof. At 210, insome embodiments, at least a part of the reforming agent is recycledafter value materials are separated from the activated silicatematerial.

Referring now to FIG. 2B and method 200′, at 203, in some embodiments,the silicate source material is subjected to a pretreatment process. Insome embodiments, pretreatment 203 includes grinding the silicate sourcematerial, heat treatment, leaching, etc., or combinations thereof. At207, in some embodiments, the activated silicate material is subjectedto a post-treatment process. In some embodiments, post-treatment 207includes cooling the activated silicate material. In some embodiments,cooling includes annealing, water/aqueous solvent quenching, oilquenching, air cooling, etc., or combinations thereof. In someembodiments, post-treatment 207 includes grinding the activated silicatematerials to produce a product having a particle size distributionbetween about 50 μm to about 800 μm. In some embodiments, the particlesize distribution is between about 100 μm to about 700 μm. In someembodiments, the particle size distribution is between about 100 μm toabout 200 μm.

Referring now to FIG. 3, and as discussed above, some embodiments ofsystem 100, namely system 100′, include process module 118 configured toinitiate a non-silicate-activation process. In some embodiments, processmodule 118 is in communication with reaction chamber 102 for intermixingthe molten slag with feedstock materials. In some embodiments, processmodule 118 utilizes molten slag provided by silicate material input 104and/or heat source 110. In some embodiments, process module 118 includesa molten slag input 300 in communication with reaction chamber 102 whichprovides the molten slag to the reaction chamber. In some embodiments,process module 118 includes a feedstock input 302 in communication withreaction chamber 102 which provides feedstock to the reaction chamber.In some embodiments, process module 118 utilizes reaction mediumprovided by reaction medium input 106. In some embodiments, processmodule 118 includes a reaction medium input 304 in communication withreaction chamber 102 which provides a reaction medium to the reactionchamber. In some embodiments, process module 118 includes a productoutput 306 in communication with reaction chamber 102. In someembodiments, process module 118 utilizes reforming agent provided byreforming agent input 108. In some embodiments, the feedstock includes areforming agent. In some embodiments, the feedstock includes a silicatemineral or legacy industrial silicate wastes. In some embodiments, thereaction medium includes certain gases. In some embodiments, the productat product output 306 includes activated silicate materials. In someembodiments, the product at product output 306 includes no activatedsilicate materials.

In some embodiments, the feedstock includes water and coal with an inertor reducing gas as the reaction medium, resulting in the product atproduct output 306 of carbon monoxide and hydrogen gas. In someembodiments, the feedstock includes water and methane with an inert orreducing gas as the reaction medium, resulting in the product at productoutput 306 of carbon monoxide and hydrogen gas. In each of theseexamples, however, little to no extra energy needs to be applied todrive the system, and thus the products are produced at essentially noenergy cost.

Examples

In order to demonstrate the HTSR method and the hydrothermal silicatereforming method are able to produce highly activated silicate materialfor carbon sequestration, experiments have been designed and conductedon two typical silicate minerals, wollastonite (CaSiO₃) and serpentine(Mg₃Si₂O₅(OH)₄), and two typical industrial silicate solid wastes, ironslag and steel slag.

In the first and second batches of experiments, the reactivity of theHTSR products was studied with different stoichiometric ratio (SR) ofthe reforming agent to the silicate based material. In the third batchof experiments, the reactivity of the HTSR products produced withdifferent reaction time, reaction environment, cooling process wasstudied. In the fourth batch of the experiments, the reactivity of theHTSR products produced with different types of reforming agents wasstudied. In the fifth batch of experiments, the reactivity of thehydrothermal reforming products was studied with lean reforming agent tomineral ratios.

Each batch of experiments consisted of three parts. First, materialactivation experiments were conducted on the aforementioned silicatematerials to produce the activated silicate material. Second, theproducts of the material activation experiments were ground and sievedso that the particle size distribution of the products can becontrolled. Third, dissolution experiments were conducted on theactivated silicate materials with controlled particle size distribution.The elemental extraction conversions of the activated silicate materialsduring the dissolution experiments were calculated.

The HTSR Experiments with the Stoichiometric Ratio of Reforming Agent

The activated silicate materials were produced by the method of HTSRwith the calculated stoichiometric ratio of mineral to reforming agent.In each experiment, a stoichiometric amount of solid sodium hydroxide(NaOH) was used as reforming agent, and mixed with wollastonite orserpentine. Then, the mixture was put into a muffle furnace at roomtemperature, and then heated up to the target reaction temperature andkept for a certain period of time. Next, the furnace is cooled down tothe ambient temperature and the product is collected. The experimentalmatrix is shown in Table 1.

TABLE 1 HTSR experimental matrix Reaction Temperature Reaction Feedstock Atmosphere (° C.) Time (min) Wollastonite Air 650 50 WollastoniteAir 1300 10 Wollastonite + NaOH Air 650 50 Wollastonite + NaOH Air 130010 Serpentine Air 650 50 Serpentine Air 1300 10 Serpentine Nitrogen 65050 Serpentine + NaOH Air 650 50 Serpentine + NaOH Air 1300 10Serpentine + NaOH Nitrogen 650 50

After these HTSR experiments, the compositions of all the samples werealso tested. The products were then ground and sieved. The particle sizedistributions of all the samples were controlled to be from 110 μm to700 μm roughly.

The activated silicate materials with controlled particle sizedistributions were then applied on a differential bed reactor to conductdissolution experiments. The solvents collected from the dissolutionexperiments were tested with Inductively Coupled Plasma Optical EmissionSpectroscopy (ICP-OES) study the concentrations of different elementsdissolved in the solvents, and the conversions of the dissolutionexperiments were calculated based on the test results.

In each dissolution experiment, nitric acid having a pH of 2 wascontinuously pumped by an HPLC pump at 10 ml/min for 60 min to reactwith 20 mg sample fixed in a sample holder. The leachate was alsocollected continuously and analyzed using ICP-OES to determine theconcentrations of different value materials in each sample. All thedissolution experiments were conducted at ambient temperature andambient pressure for 1 hour.

The extraction conversions of the major value materials of theserpentine related materials under study are shown in FIGS. 4A-4C. Theextraction conversions of the major value materials of the wollastoniterelated materials under study are shown in FIGS. 4D-4E.

The HTSR Experiments at Lean Reforming Agent to Mineral Ratios

In this batch of experiments, the activated silicate materials wereproduced by the HTSR process with lean reforming agent to mineralratios. In each experiment, solid sodium hydroxide (NaOH) was used asthe reforming agent, and mixed with wollastonite, serpentine, air coolediron slag (AC IS) or air cooled steel slag (AC SS) at a certain ratio(0.1 stoichiometric ratio and 1 stoichiometric ratio). Then, the mixturewas put into a muffle furnace at room temperature, and the furnace washeated up to the target reaction temperature and kept for a certainperiod of time. Next, the furnace was cooled down to the ambienttemperature and the product was collected. The experimental matrix isshown in Table 2.

TABLE 2 HTSR experimental matrix Reaction Reaction Temperature Time Feedstock Atmosphere (° C.) (min) Wollastonite (HT Wol) Air 1300 10Wollastonite + NaOH (SR) Air 1300 10 (WolNaOH) Wollastonite + NaOH (0.1Air 1300 10 SR) (Wol0.1NaOH) Serpentine (HT Serp) Air 1300 10Serpentine + NaOH (SR) Air 1300 10 (SerpNaOHF1300) Serpentine + NaOH(0.1 SR) Air 1300 10 (Serp0.1NaOHF1300) Serpentine (SerpF650) Air 650 10Serpentine + NaOH (0.1 SR) Air 650 10 (Serp0.1NaOHF650) Iron Slag + NaOH(SR) Air 1300 10 (ISNaOH) Iron Slag + NaOH (0.1 SR) Air 1300 10(IS0.1NaOH) Steel Slag + NaOH (SR) Air 1300 10 (SSNaOH) Steel Slag +NaOH (0.1 SR) Air 1300 10 (SS0.1NaOH)

After these HTSR experiments, the compositions of all the samples werealso tested. The products are then ground and sieved. The particle sizedistributions of all the samples are controlled to be from 106 μm to 208μm. All the dissolution experiments were conducted at ambienttemperature and ambient pressure for 1 hour.

The extraction conversion results of the major elements of the samplesare shown in FIGS. 5A-5D.

The HTSR Experiments at Lean Reforming Agent to Mineral Ratios withDifferent Reaction Temperatures, Reaction Times and Reaction Atmospheres

In this batch of experiments, the activated silicate materials wereproduced by the HTSR process with 0.1 of the stoichiometric ratio ofreforming agent to mineral with different reaction times, reactionatmospheres and cooling processes. In each experiment, solid sodiumhydroxide (NaOH) was used as reforming agent and mixed with serpentine.Then, the mixture was put into a muffle furnace with a certainatmosphere at room temperature and the furnace was heated up to thetarget reaction temperature and kept for a certain period of time. Next,the product was cooled down to the room temperature with a certaincooling process. The experimental matrix is shown in Table 3.

TABLE 3 HTSR experimental matrix Reaction Cooling Reaction Feed stockAtmosphere Temperature (° C.) Process Time (min) Serpentine (SerpF650)Air 650 Annealing 10 Serpentine + NaOH (0.1 SR) Air 650 Annealing 10(Serp0.1NaOHF650) Serpentine + NaOH (0.1 SR) Air 650 Annealing 60(Serp0.1NaOHF6501hr) Serpentine (SerpN2F650) N2 650 Annealing 10Serpentine + NaOH (0.1 SR) N2 650 Annealing 10 (Serp0.1NaOHN2F650)Serpentine + NaOH (SR) N2 650 Annealing 60 (SerpNaOHN2F6501hr)Serpentine + NaOH (SR) Air 650 Annealing 60 (SerpNaOHF6501hr) Serpentine(HT Serp) Air 1300 Annealing 10 Serpentine + NaOH (0.1 SR) Air 1300Annealing 10 (Serp0.1NaOH) Serpentine + NaOH (0.1 SR) Air 1300 Water 10(Serp0.1NaOHWQ) Quenching Serpentine + NaOH (0.1 SR) Air 1300 Air 10(Serp0.1NaOHAC) Cooling

After the reforming experiments, the compositions of all the sampleswere also tested. The products were then ground and sieved. The particlesize distributions of all the samples were controlled to be from 106 μmto 208 μm. All the dissolution experiments were conducted at ambienttemperature and ambient pressure for 1 hour.

The extraction conversion results of the major elements of the samplesare shown in FIGS. 6A-6C.

The HTSR Experiments at Lean Reforming Agent to Mineral Ratios withDifferent Reforming Agents

In this batch of experiments, the activated silicate materials wereproduced by the method of HTSR with 0.1 of the stoichiometric ratio ofreforming agent to mineral with different types of fluxing agents. Ineach experiment, the fluxing agent was mixed with serpentine. Then, themixture was put into a muffle furnace at room temperature, and thefurnace was heated up to the target reaction temperature and kept for acertain period of time. Next, the product was cooled down together withthe furnace to the room temperature. The experimental matrix is shown inTable 4.

TABLE 4 HTSR experimental matrix Reaction Reaction Temperature Time Feedstock Atmosphere (° C.) (min) Serpentine (HT Serp) Air 1300 10Serpentine + KOH (0.1 SR) Air 1300 10 (Serp0.1NaOH) Serpentine + NaOH(0.1 SR) Air 1300 10 (Serp0.1NaOH) Serpentine + LiOH (0.1 SR) Air 130010 (Serp0.1LiOH) Serpentine + Na₂CO₃ (0.1 SR) Air 1300 10(Serp0.1Na2CO3) Serpentine + LiBO₂ (0.1 SR) Air 1300 10 (Serp0.1LiBO2)Serpentine + Li₂B₄O₇ (0.1 SR) Air 1300 10 (Serp0.1Li2B4O7) Serpentine +NaCl (0.1 SR) Air 1300 10 (Serp0.1NaCl) Serpentine + LiCl (0.1 SR) Air1300 10 (Serp0.1LiCl) Serpentine + B₂O₃ (0.1 SR) Air 1300 10(Serp0.1B2O3)

After the reforming experiments, the compositions of all the sampleswere also tested. The products are then ground and sieved. The particlesize distributions of all the samples were controlled to be from 106 μmto 208 μm. All the dissolution experiments were conducted at ambienttemperature and ambient pressure for 1 hour.

The extraction conversion results of the major elements of the samplesare shown in FIG. 7.

The Hydrothermal Reforming Experiments at Lean Reforming Agent toMineral Ratios

In this batch of experiments, the activated silicate materials wereproduced by the method of hydrothermal reforming with 0.1 of thestoichiometric ratio of reforming agent to mineral. In each experiment,0.1 stoichiometric amount of NaOH was mixed with serpentine orwollastonite. Then, the mixture was put into DI water to prepare aslurry of 15 percent by weight. Then, the mixture was put into a closedreactor, which was then pressurized and heated up to the target reactiontemperature and kept for a certain period of time. Next, the product wascooled down to room temperature. The experimental matrix is shown inTable 5.

TABLE 5 Hydrothermal reforming experimental matrix Reaction ReactionTemperature Time Feed stock Atmosphere (° C.) (min) Serpentine + NaOH(0.1 SR) Air 185 120 (SerpHTA) Wollastonite + NaOH (0.1 Air 185 120 SR)(WolHTA)

After the hydrothermal reforming experiments, the compositions of allthe samples were also tested. The products were then ground and sieved.The particle size distributions of all the samples were controlled to befrom 106 μm to 208 μm. All the dissolution experiments were conducted atambient temperature and ambient pressure for 1 hour.

The extraction conversion results of the major elements of the samplesare shown in FIGS. 8A and 8B.

Systems and methods of the present disclosure yield, via a reformingreaction with a reforming agent, a silicate material product from eithernatural or man-made (i.e., industrial byproduct) sources that isactivated and highly reactive. By this activation, the kinetics andconversion of the elemental extraction process with the activatedsilicate materials are improved as compared to that with non-activatedsilicate material. Thus the value materials within the activatedsilicate material, e.g., Ca, Mg, Fe, Al, Si, etc., can be readilyextracted for use in other processes. Additionally, the activatedsilicate material becomes a desirable target for sequestration of carbondioxide.

The silicate is activated by reacting with a reforming agent viahydrothermal or HTSR processes. These hydrothermal and HTSR processescan activate the silicate material using industrial waste energy andrecyclable material, so that the overall energy cost and consumptionassociated with activating the silicate materials are reduced. Further,the hydrothermal and HTSR processes can be integrated with otherprocesses such as coal gasification or steam reforming, increasing thebenefit provided by the recycled industrial waste energy and material.

Although the disclosed subject matter has been described and illustratedwith respect to embodiments thereof, it should be understood by thoseskilled in the art that features of the disclosed embodiments can becombined, rearranged, etc., to produce additional embodiments within thescope of the invention, and that various other changes, omissions, andadditions may be made therein and thereto, without parting from thespirit and scope of the present invention.

What is claimed is:
 1. A method of producing activated silicate materialcomprising: providing a silicate source material; intermixing areforming agent with the silicate source material; providing heat from awaste heat source to the silicate source material and the reformingagent to initiate a reforming reaction; reforming the silicate sourcematerial to an activated silicate material via a hydrothermal process ora high temperature silicate reforming process; extracting valuematerials from the activated silicate material; and recycling at least apart of the reforming agent.
 2. A system for producing activatedsilicate material comprising: a reaction chamber; a silicate materialinput in communication with the reaction chamber configured to provide asource of silicate material to the reaction chamber; a reforming agentinput in communication with the reaction chamber configured to provide asource of reforming agent to the reaction chamber; a reaction mediuminput in communication with the reaction chamber configured to provide areaction medium to the reaction chamber; at least one conduit positionedto communicate the silicate material, the reforming agent, and thereaction medium input to the reaction chamber; a heat source configuredto provide heat to the system; and an activated silicate material outputfrom the reaction chamber.
 3. The system according to claim 2, whereinthe silicate material source comprises a water-based slurry.
 4. Thesystem according to claim 2, wherein the silicate material source is acalcium mineral, a magnesium mineral, slag, mine tailing, fly ash, kilndust, or a combination thereof.
 5. The system according to claim 2,wherein the heat source is an industrial energy production source, anindustrial energy production process, waste energy source, molten ironslag, molten steel slag, a flue gas, an exhaust gas, exhausted steam, ora combination thereof.
 6. The system according to claim 2, wherein thereaction medium is an industrial plant exhaust source, air source,nitrogen gas source, oxygen gas source, carbon monoxide gas source, or acombination thereof.
 7. The system according to claim 3, furthercomprising a process module in communication with the silicate materialsource configured to initiate a non-silicate-activation processutilizing heat from molten slag, wherein the silicate material is themolten slag, wherein the non-silicate-activation process is anendothermic reaction.
 8. The system according to claim 7, wherein theprocess module comprises a feedstock input in communication with thereaction chamber configured to provide a feedstock to the reactionchamber.
 9. The system according to claim 3, further comprising anelemental extraction module for extracting value materials from theactivated silicate material.